Audi A4 Avant 95-01 Service & Repair Manual

20-1

Fuel supply system, servicing

guidelines

Safety precautions

WARNING!

When removing and installing fuel pump or

fuel gauge sensor from a partially filled fuel

tank:

BEFORE beginning work, place exhaust

extraction system suction pipe near fuel tank

opening so escaping fuel vapors can be

immediately sucked off.

If no exhaust extraction system is available,

use a radial fan (with motor located outside

airflow) with volume of at least 9 cfm.

Wear fuel-resistant gloves whenever working

with open parts of the fuel system.

Be sure the ignition is switched off when:

Disconnecting fuel injection system wiring.

Connecting or disconnecting test equipment

leads.

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BEFORE cranking the engine at starting RPM

(such as compression testing) disable the

fuel injection and ignition systems:

Disconnect the ignition coil power output

stage.

Disconnect harness connectors from all fuel

injectors.

After the work is completed, erase

Diagnostic Trouble Code (DTC) memory.

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20-2

WARNING!

Fire hazard! Do NOT have anything in the

area that can ignite gasoline!

Fuel system is under pressure! Before

opening, place clean cloths around the

connections to be opened. Carefully loosen

the connections to relieve pressure.

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20-3

CAUTION!

BEFORE disconnecting the battery:

Stop the engine.

Be sure the ignition is switched off (also

applies when connecting the battery). Failure

to do so may damage the Engine Control

Module (ECM).

Be sure of the proper radio code (for vehicles

equipped with coded anti-theft radio)

Be sure the battery negative (-) cable is

disconnected, when:

Working on the electrical system.

Resistance (spot) welding or electric arc-

welding anywhere on the vehicle.

When connecting and disconnecting

electrical test equipment (LED voltage tester,

multimeter, etc.)

Be sure the ignition is switched off.

Use correct adapters from VW 1594

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connector test kit.

Always refer to the latest parts catalog to

ensure that you use original equipment fuel

hose clamps.

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20-4

Rules of cleanliness

CAUTION!

Whenever working on the fuel supply and fuel

injection systems, carefully observe the

following five rules of cleanliness:

1.- Thoroughly clean fuel system lines and hose

connections and surrounding area before

disconnecting.

2.- Place removed components on a clean

surface and cover them. Use plastic sheeting or

paper. Do not use fluffy rags that could leave

lint.

3.- Carefully cover or seal any components that

have been opened if repairs are not carried out

immediately.

4.- Install only clean parts. Do not remove

replacement parts from the packaging until

immediately before they are installed.

Do not use parts that have been stored without

packaging (from toolboxes, for example).

5.- When fuel system is opened avoid working

with compressed air whenever possible. Avoid

moving the vehicle if possible

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20-5

Observe following points before working on the

fuel supply system

CAUTION!

Obtain the radio Anti-theft code from the

customer before disconnecting the Battery

Ground strap.

With ignition switched OFF, disconnect Battery

Ground strap.

Open the fuel filler cap briefly and close

again.

Observe the following precautions when

removing or installing components from a filled or

partially filled fuel tank.

WARNING!

Empty the fuel tank before removal! If it is not

empty, the weight and sloshing fuel could

lead to injury, component damage or possible

fuel spillage.

Fuel tank must not be filled more than

1

/

3

maximum.

Reduce fuel quantity using fuel cart, if

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necessary.

Do NOT allow fuel to contact skin! Wear fuel-

resistant gloves!

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20-6

Fuel supply system, servicing

(vehicles with front wheel drive

and 1.8 ltr. turbo or 2.8 ltr.

engine)

Note:

CAUTION!

Always refer to the latest parts catalog to

ensure that you use original equipment fuel

hose clamps.

VAG1921 spring clamp pliers are recommended

for installation

Always replace seals, O-rings and gaskets

during installation work.

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20-7

Fuel tank assembly, component overview

Note:

Always refer to the Parts Catalog for availability of

individual items in an assembly.

Vehicles with front wheel drive and 1.8 ltr. turbo

or 2.8 ltr. engine

1 -

Return line

From engine

- Mark before removing

- Note direction of arrow on connecting

flange

2 -

20 Nm

3 -

Fuel filter

Location: Arrow points in flow direction.

4 -

Holding clamp

For fuel filter

5 -

Supply line

To the fuel filter

- Mark before removal

- Note direction of arrow on connecting

flange

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20-8

6 -

Mounting screw

25 Nm

To connect fuel-filler neck and Ground

(item 13 Page 20-8 )

7 -

Washer

8 -

Overflow hose

9 -

Rubber cap

10 -

Locking ring

11 -

Sealing ring

- Replace if damaged.

12 -

Cover

13 -

Ground connection

Location Fig. 1 , Page 20-10

- Connect wiring terminal with mounting

screw (item 6 ) Page 20-8 .

- After installing, check continuity between

metal ring on fuel filler neck and bare

chassis Ground point. spec: approx. 0

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20-9

14 -

Bleed line

To EVAP canister

15 -

Fuel tank

Removing and installing Page 20-19

16 -

25 Nm

- Note tightening sequence Page 20-23

17 -

Bracket

For clamp bands

18 -

Clamp bands

Removing and installing Page 20-19

- Note different lengths

- Note installation direction

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20-10

Fig. 1 Ground connection installation position

- Route Ground connection -arrow-, as shown in illustration.

- Ensure tight fit of electrical Ground connection to fuel filler neck Ground

clamp.

CAUTION!

After installation, check for continuity between Ground clamp on

filler neck and chassis Ground.

- Attach wiring terminal -1- with screw -2- for fuel filler neck.

Specification: approximately 0 .

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20-11

Fuel filler neck, component overview

(vehicles without ORVR)

Vehicles with front wheel drive and 1.8 ltr. turbo

or 2.8 ltr. engine

1 -

Ground connection

Location Fig. 1 , Page 20-10

- Ensure tight fit of connector on filler neck

ring

- Connect wiring terminal with mounting

screw for plastic fuel filler neck (item 6

Page 20-8 )

- After installing, check continuity between

metal ring on fuel filler neck and chassis

Ground. Specified: approx. 0

2 -

Bleed line

To EVAP canister

3 -

Gravity valve

To remove valve, unclip upward out of the

filler neck

- Check valve for flow:

Valve vertical: open,

Valve tipped 45 : closed

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20-12

4 -

O-ring

-Replace

5 -

O-rings

-Replace

6 -

Bleed valve

Removing, installing, checking Fig. 1 ,

Page 20-13

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20-13

Fig. 1 Bleed valve removing, installing, checking

- To remove, unclip valve from side of filler neck.

Lever in rest position: Valve closed

Lever pressed in direction of arrow: Valve open

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20-14

Fuel filler neck, component overview

(vehicles with ORVR)

Vehicles with front wheel drive and 1.8 ltr. turbo

or 2.8 ltr. engine

1 -

Bleed line

To top of filler neck on fuel tank

2 -

Expansion tank

Clipped to fuel-filler neck

3 -

Tank ventilation valve

Clipped to fuel-filler neck

Ventilates fuel tank for pressure

compensation

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20-15

4 -

Ground connection

Location Fig. 1 , Page 20-10

- Ensure tight fit of connector on filler neck

ring

- Connect wiring terminal with mounting

screw for plastic fuel filler neck (item 6

Page 20-8 ).

- After installing, check continuity between

ring on fuel filler neck and chassis

Ground, spec: approx. 0

5 -

Gravity valve

To remove valve, unclip upward out of filler

neck

- Check valve for flow:

Valve vertical: Flow

Valve tipped 45 : No Flow

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20-16

6 -

O-ring

-Replace

7 -

Sealing ring

Installation position: Sealing lip points to

the fuel filler neck

8 -

O-rings

Different sizes

-Replace

9 -

Bleed valve

Removing, installing, checking Fig. 1 ,

Page 20-17

10 -

Bleed line

To EVAP canister

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20-17

Requirement

Tab -2- pressed in direction of arrow:

Tab -2- in OFF position:

Fig. 1 Bleed valve, removing, installing, checking

Fuel tank removed

- To remove, unclip valve from side of filler neck.

- Plug port -3- by hand.

- Blow into port -1-

Must be flow

Must NOT be flow.

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Audi A4 Avant 95-01 Service & Repair Manual

Audi A4 Avant 95-01 Service & Repair Manual

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